S J Maddox - Böcker

The weld toe is a primary source of fatigue cracking because of the severity of the stress concentration it produces. Weld toe improvement can increase the fatigue strength of new structures significantly. It can also be used to repair or upgrade existing structures. However, in practice there have been wide variations in the actual improvements in fatigue strength achieved. Based on an extensive testing programme organised by the IIW, this report reviews the main methods for weld toe improvement to increase fatigue strength: burr grinding, TIG dressing and hammer and needle peening. The report provides specifications for the practical use of each method, including equipment, weld preparation and operation. It also offers guidance on inspection, quality control and training as well as assessments of fatigue strength and thickness effects possible with each technique. IIW recommendations on methods for improving the fatigue strength of welded joints will allow a more consistent use of these methods and more predictable increases in fatigue strength.

This report provides background and guidance on the use of the structural hot spot stress approach to the fatigue design of welded components and structures. It complements the IIW recommendations for 'Fatigue Design of Welded Joints and Components' and extends the information provided in the IIW recommendations on 'Stress Determination for Fatigue Analysis of Welded Components'. This approach is applicable to cases of potential fatigue cracking from the weld toe. It has been in use for many years in the context of tubular joints. The present report concentrates on its extension to structures fabricated from plates and non-tubular sections.Following an explanation of the structural hot spot stress, its definition and its relevance to fatigue, the authors describe methods for its determination. Stress determination from both finite element analysis and strain gauge measurements is considered. Parametric formulae for calculating stress increases due to misalignment and structural discontinuities are also presented. Special attention is paid to the use of finite element stress analysis and guidance is given on the choice of element type and size for use with either solid or shell elements. Design S-N curves for use with the structural hot spot stress are presented for a range of weld details. Finally, practical application of the recommendations is illustrated in two case studies involving the fatigue assessment of welded structures using the structural hot spot stress approach.

The key to avoidance of fatigue, which is the main cause of service failures, is good design. In the case of welded joints, which are particularly susceptible to fatigue, design rules are available. However, their effective use requires a good understanding of fatigue and an appreciation of problems concerned with their practical application. Fatigue strength of welded structures has incorporates up-to-date design rules with high academic standards whilst still achieving a practical approach to the subject. The book presents design recommendations which are based largely on those contained in recent British standards and explains how they are applied in practice. Attention is also focused on the relevant aspects of fatigue in welded joints which are not yet incorporated in codes thus providing a comprehensive aid for engineers concerned with the design or assessment of welded components or structures. Background information is given on the fatigue lives of welded joints which will enable the engineer or student to appreciate why there is such a contrast between welded and unwelded parts, why some welded joints perform better than others and how joints can be selected to optimise fatigue performance.